Inverter Technology 175 210 188GE

Cod.
988672
TECHNOLOGY 175-210-188CE/GE TECNICA 140.1 - 142
inver ter
TROUBLESHOOTING AND REPAIR MANUAL

CONTENTS
PAGE
OPERATION AND WIRING DIAGRAMS................ 2 Block diagram 2 Analysis of the block diagram 3 Illustrations 5 Wiring diagrams 6 REPAIR GUIDE.......................................................11 Equipment required 11 General repair instructions 12 Troubleshooting and remedies 12 Testing the machine 15 Illustrations 18 SPARE PARTS LIST...............................................19 REPAIR SHEET......................................................23
reparation
no
problem !
INPUT
INDUCTANCE AND SHUNT
EMC FILTER CURRENT TRANSFORMER POWER TRANSFORMER SECONDARY DIODES SECONDARY EMC FILTER
RECTIFIER BRIDGE
PRE-CHARGE CHOPPER
FILTER
OUTPUT
BLOCK DIAGRAM
1 7
2 5 6 8 10
POWER SUPPLY LED

TERTIARY SUPPLY
AUXILIARY SUPPLY
FAN
SEPARATOR TRANSFORMER
DRIVER IGBT
28
11 29
13
14
12
TRANSFORMER PILOT
DUTY CYCLE MAKER
PRIMARY CURRENT READER AND LIMITER

SHUNT AMPLIFIER
15 16
24
18
UNDERVOLTAGE SAFEGUARD
ALARM BLOCK
ADDER
27
19 17
CONTROL
SECONDARY DIODE THERMOSTAT
POWER TRANSFORMER THERMOSTAT
ALARM LED
OPERATION AND WIRING DIAGRAMS
26
25
20
MAXIMUM CURRENT ADJUSTMENT
TECHNOLOGY 175-210-188CE/GE
-2+
|
23
CURRENT POTENTIOMETER
21
WELDING PROCEDURE FUNCTION SELECTOR
MMA
22
TIG -LIFT
ANALYSIS OF THE BLOCK DIAGRAM
NOTE: Unless indicated otherwise, it should be assumed that the components are assembled on the power board.
Block 9
Inductance and shunt Consisting of: L1, R38. The inductance levels the secondary board diodes' output current making it practically continuous/direct. The shunt reads the current circulating in the inductance and sends it to block 24 (shunt amplifier), which will process the data.
Block 1
EMC Filter Consisting of: C24, C25, C26, L2. Prevents noise from the machine from being transmitted along the main power line and vice versa.
Block 10
Secondary EMC Filter Consisting of: C21, C22. Prevents noise from the power source from being transmitted through the welding cables and vice versa.
Block 2
Rectifier bridge Consisting of: D31, D32. Converts the mains alternating voltage into continuous pulsed voltage.
Block 11
Auxiliary supply Constisting of: T2, D1, Q2, U5 Takes and stabilizes the voltage coming from block 2 (rectifier bridge) and makes it suitable to supply correctly: block x (supply led) block x (transformer separator) and block 3 (precharge).
Block 3
Pre-charge Consisting of: K1, K2, R40. Prevents the formation of high transitory currents that could damage the main power switch, the rectifier bridge and the electrolytic capacitors. When the power source is switched on the relay K1 and K2 are de-energised, capacitors C27, C29, C30, C31 are then charged by R40 When the capacitors are charged the relay is energised.
Block 12
Tertiary supply Constisting of: D11, D57, Q0,D8 Takes and stabilizes the voltage coming from tertiary wiring block 7 (power transformer) and makes it suitable to supply correctly block x (fans) and block 3 (pre-charge).
Block 4
Filter Consisting of: C27, C29, C30, C31. Converts the pulsed voltage from the rectifier bridge into continuous voltage.
Block 13
Separator transformer
Consisting of: T3. Supplies two signals, which are separated galvanically from one another, that will be sent to power block 14 (driver).
Block 5
Chopper Consisting of: Q6, Q7, Q8, Q9. Converts the continuous voltage from the filter into a high frequency square wave capable of piloting the power transformer. Regulates the power according to the required welding current/voltage.
Block 14
Driver Consisting of: Q5, D19, D20, Q10, D25, D26. Takes the signal from block 13 (flyback power supply) and, controlled by block 15 (duty cycle maker), makes the signal suitable for piloting block 5 (chopper).
Block 6
Current transformer Consisting of: T1. The C.T. is used to measure the current circulating in the power transformer primary and transmit the information to block 17 (primary current reader and limiter).
Block 15
Transformer Pilot
Consisting of: Q4, D14, D15, D16. Amplifies the signal arriving from block 16 (duty cycle maker), needed to pilot block 13 (separator transformer).
Block 7
Power transformer Consisting of: T4. Adjusts the voltage and current to values required for the welding procedure. Also forms galvanic separation of the primary from the secondary (welding circuit from the power supply line).
Block 16
Duty cycle maker Consisting of: U2 (control board). Processes the information from block 17 (adder) and block 18 (primary current reader and limiter) and produces a square wave with variable duty cycle limiting the primary current to a maximum pre-set value under all circumstances.
Block 8
Secondary diodes Consisting of: D46, D47, D48, D49, D51. D46, D47, D48 converts the current circulating in the transformer to a single direction, preventing saturation of the nucleus. D49, D51 recirculate the inductance output current (block 9) when the IGBT's are not conducting, bypassing the power transformer (block 7).
-3-
Block 17
Adder Consisting of: U1C (control board). Gathers all the information from block 18 (primary current reader and limiter), from block 19 (alarms) and from block 21 (current potentiometer), and produces a signal with a suitable voltage for processing by block 16 (duty cycle maker).
Block 18
Primary current reader and limiter Consisting of: R79, R80, R81, R82, R83, R84 (control board). Reads the signal from block 6 (current transformer) and scales it down so it can be processed and compared in block 16.
Block 27
Undervoltage safeguard Consisting of: R7, R9 and part of control board. If the main supply voltage falls below the minimum allowed value this safeguard triggers (a tolerance of approx. 15% of the power supply voltage is allowed: outside this range the safeguard triggers).
Block 19
Alarm Block Consisting of: U1A (control board). When an alarm is detected the power source output current is drastically reduced by making direct adjustments to block 16 (duty cycle maker) and directly changing the reference signal obtained from block 21 (current potentiometer).
Block 28
Power supply LED Consisting of: D43. Indicates when the power source is correctly powered and ready for use.
Block 20
Alarm LED Consisting of: D39. It is switched on by block 19 (alarms) in the event of: 1) Triggering of thermostatic capsule/thermostat on power transformer.
Block 29
Fan Consisting of: V1, V2. Powered directly by block 12 (Tertiary supply) and cools the power components.
2) Triggering of thermostatic capsule on secondary diodes.

3) Triggering due to undervoltage. 4) Short circuit at output (electrode holder clamp and earth cable connected to one another or electrode stuck to piece being welded).
Block 21
Current potentiometer Consisting of: R49. This is used to set the reference voltage needed to adjust the output current: when the potentiometer knob is turned the cursor voltage varies, thus varying the current from the minimum to the maximum value.
Block 22
Welding procedure function selector Consisting of: SW1 The switch is used to select the type of welding process: MMA, TIG-LIFT.
Block 23
Maximum current adjustment Consisting of: R48, R55. Used to adjust the maximum cutting current to be supplied by the power source.
Block 24
Shunt Amplifier Consisting of: U3A (control board) Amplifies the signal from block 9 (inductance shunt) and makes it appropriate for block 17 ( Adder).
Block 25
Power transformer thermostat Consisting of: ST2. When the temperature of the power transformer is too high, the thermostat transmit the information to block 19 (Alarm Block). It is reset automatically after the alarm condition has ceased.
Block 26
Secondary diode thermostat Consisting of: ST1 When the temperature of the secondary diode dissipator reaches a given temperature the thermostat cuts in, sending an alarm signal to block 19 (Alarm Block). It is reset automatically when this alarm condition is no longer present.
-4-
ILLUSTRATIONS
Power board
(21) CURRENT POTENTIOMETER
(28)
POWER SUPPLY LED
(20)
ALARM LED
(22) WELDING PROCEDURE FUNCTION SELECTOR
(10) SECONDARY FILTER EMC
CONTROL BOARD
(9) INDUCTANCE AND SHUNT
(8) SECONDARY DIODES
(7) POWER TRANSFORMER
(11) AUXILIARY POWER SUPPLY (6) CURRENT TRANSFORMER
(2) PRE-CHARGE
(15) TRANSFORMER PILOT
(3) RECTIFIER BRIDGE
(13) SEPARATOR TRANSFORMER
(1) PRIMARY EMC FILTRE
(5) CHOPPER
(4) FILTER
-5-
WIRING DIAGRAMS
POW E R PCB CON T RO L PCB

CN11
J7 J3
PE
L1 CN4 CN9
L1
Indu ttance
N (L2 )
S1 ON / F F O
ON LY FOR G E V E R S ON I
+5V +17V8 D R+ GND T A+ TA SH S H+ VO L T VO L T+ PO T _ IN T AR+ T AR VCH ECK FAU L T
V1+
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
SW LED GND
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Wiring general diagram - TECHNOLOGY 175 - 210 -188 CE/GE
-6V1J21 V 2+ SH V2R 38 S hun t J22
V1 F an
O U T+
OU T -
V2 F an
MOD E L
G B T Q6 ,Q7 , I Q8 ,Q9 SGW 30N60 SGW 30N60 SGW 30N60 470u 450V A ll 470u 450V A ll D31 = 36M B 100A D32 = N M . . ON O FF 33K 0W 25 5% K1 = 15Vdc 45 mA /250V 16A K2 = 15Vdc 45 mA /250V 16A NM. . 680u 400V A ll D31 =G B PC3508 /10 D32 =G B PC3508 /10 O FF ON 10K 0W 25 5% K1 = 15Vdc 45 mA /250V 16A K2 = 15Vdc 45 mA /250V 16A NM. . 470u 400V A ll D31 =G B PC3508 /10 D32 =G B PC3508 /10 O FF ON 27K 0W 25 5% K1 = 15Vdc 45 mA /250V 16A K2 = 15Vdc 45 mA /250V 16A
C28
C29 ,C30 ,C31
D31 , D32
K1 , K 2
JP 1
JP 2
R 55
T ECHNO LOG Y 175
T ECHNO LOG Y 210
T ECHNO LOG Y 188G E / E C
T P1 T P2 T P3 JP 1 V .T . Q7 V .T . C33 10n 630V K P K2 V .T .
JP 2 V .T . Q6 V .T .
R 40 47R 8W 5% T P 39 R 42 1R 0W 25 5% D34 NM. . R 44 20R 13W 5% D33 R U R P 860
CN4
L2 295uH
D31 V .T .
T P 40 R 43 1R 0W 25 5%
Fas ton- 6 ,3x0 ,8 M H2 D is s patore i H3 D is s patore i T P 37 R 46 1R 0W 25 5% Q8 V .T . T P 38 Q9 V .T .
C24 1u 275V M K P K1 V .T .
R 39 1M 0W 5 5%
H1
CN9
D is s patore i
D37 M U R 1560
Fas ton- 6 ,3x0 ,8 M
T P4 T P5 T P6
Wiring diagram power board - primary
CN11 C28 NM. . R 14 3K 3 5W 10% C29 V .T . C30 V .T . C31 V .T . C27 220n 630V M K P R 47 1R 0W 25 5%
D36 NM. .
R 45 20R 13W 5%
D35 R U R P 860
Fas ton- 6 ,3x0 ,8 M
CN8
C25 4n7 250V K P
C26 4n7 250V K P
D32 V .T .
C34 10n 630V K P
D38 M U R 1560
NM. . P ower board T echno ogy_B l R E LE _K2_A R E LE _K2_B R E LE _K1_A R E LE _K1_B AC+ AC T P 22 VCH ECK DR+ Power board T echno ogy_C l
R 49 10K L IN 0W 2 10%
R 48 47K 20 T 0W 5 10%
G A T E _H
E M E T _H
GA T E _ L
EM E T _ L
T A+
TA -
SH -
S H+
VO L T R E LP R E LP
D R+
F15246B
F15246C
J7
F o r i 22 pa s so 2 .5
T P7
SW 1 1B 11 TG I
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 T P 17 +17V8
T A+ TA SH S H+ VO L T VO L T+ PO T IN T A R+ TAR VC H E C K FAU L T C A DM C AD A C AD 1 C AD 2 SW LED
+17V8 T P 9
T P 18 T P 19 T P 20
T P 16
MMA B T P 10 R 50 2K 2 0W 25 5%
B +5V
F o r i_ 12 pa s so 2 .5
J8
R 12 NM. . B
C 35 1u 63V M K T
T P 23
1 2 3 4 5 6 7 8 9 10 11 12
R 13 NM. . D 40 1N 4148
D39 G a llo 5 i mm
C44 100u 25V A ll
T P 24
D41 1N4148
VO L T +
T E R M CO I
-7SP S P+ R 57 NM. .
T P8
T P 11
+5V
T P 21
CO R R
MAX I
T R A FO _PN T R A FO _P P SP S P+
+5V +17V 8
R 55 V .T .
R 56 NM. .
20V C14 NM. . D2 1N4004 T P 26 Q2 T IP 50 U5 1 IN GND C6 10u 25V A ll 1 D55 D7 10V 0W 4 5% C1 470u 50V A ll C42 33u 25V A ll D3 18V 1W 5% C2 10u 25V A ll C3 470u 25V A ll R9 12K 0W 25 5% 2 no so der l 3 VCH ECK 10V 0W 4 5% B 2 Q1 M P S A13 D56 NM. . R 59 10K 0W 25 5% D54 1N4148 R E LE _K1_B R E LE _K1_A LM 78L05 3 OU T H4 C40 33u 25V A ll 2 R 58 22R 0W 5 5% D4 1N4148 T P 27 +5V +17V8
+17V8
T P 25
T2 230 /18 4VA
D1 W 02G R1 470R 2W 5%
R 51 3K 3 0W 5 5%
AC+
AC -
D43 Verde 5 mm
1 no so der l
C36 T P 29 1n 100V X7R T P 28
D11 B Y V27-200 V1 12Vdc +V2 V2 12Vdc
D10 B Y V27-200
C37 1n 100V X7R
S P+ R8 3K 3 0W 5 5% +V1
H4 Q0 T IP 122
R E LP
D57 B Y V27-200
Wiring diagram power board - power / driver
C11 100u 63V A ll
C10 1u 63V M K T
C9 1u 63V M K T
C38 1u 63V M K T
C39 1u 63V M K T
D8 15V 0W 4 2%
C43 47u 25V A ll
-V1
-V2
D6 1N4148
C8 100N 63V M K T
R E LE _K2_A R E LE _K2_B
D 18 B Y V 27 -200 3
D R+ D 17 B Y V 27 -200 1
Q4 IR FD 110
-8D 19 B Y V 27 -200 R 28 120R 0W 25 5% C 19 NM. . Q5 BC 327 10R 0w25 5% R 31 D21 18V 0W 4 5% T P 30 D 20 B Y V 27 -200 D 52 NM. . D22 18V 0W 4 5% T P 32 4 C 16 1u 63V M K T R 29 470R 0W 25 5% R 30 1K 0W 25 5% 3 5 D 25 B Y V 27 -200 R 27 120R 0W 25 5% D 26 B Y V 27 -200 D 53 NM. . R 33 10R 0W 25 5% T P 31 D23 18V 0W 4 5% C 18 NM. . Q 10 BC 327 6 D24 18V 0W 4 5% T P 33 C 17 1u 63V M K T R 34 470R 0W 25 5% R 32 1K 0W 25 5%
SP -
GA T E _H
+17V 8
D 14 10V 0W 4 5%
T3 T I 117303
D 15 10V 0W 4 5%
EM E T _H GA T E _L
D 16 B Y V 27 -200
C 41 33u 25V A ll
C 15 1u 63V M K T
T P 34
R 25 220R 0W 25 5%
R 26 1K 0W 25 5%
EM E T _L
R E LP T P 35 J2 IN /OU T R 35 1K5 0W 25 5% T P 36
J1 IN /OU T R 11 10K 0W 25 5% Q3 BC337
T E RM CO I
MOD E L C20 100n 63V M K T B D47 = N M . . D47 = S T T H 6003CW B R 60 1K 0W 25 5%
D46 , D48
D47
T ECHNO LOG Y 175 T ECHNO LOG Y 210 D46 = N M . . T ECNO LOG Y 188CE / E D48 = N M . G . D46 = S T T H 6003CW D48 = S T T H 6003CW
D46 = S T T H 6003CW D48 = S T T H 6003CW D47 = N M . .
D44 NM. . 3 D46 V .T . VO L T S T1 80 C VO L T+
Wiring diagram power board - secondary
H4 1
D 48 V .T . 3 D 27 NM. . D49 S T T H 6003CW D50 NM. . H5 1 2 1
T R A FO _P P
C 32 1n5 630V K P
-93 D47 V .T . D29 NM. . R 41 10R 5W 5% T P 15 T P 14 J5 S P+ SP J6 T P 12 T P 13 TA T A+
J21
OU T+
Foro
S T2 110 C
D30 NM. .
R 37 100K 0W 25 5% 2 D51 S T T H 6003CW
C21 10n 300V M K P JP 4 so der l C22 10n 300V M K P L1 11uH R 38 180A = 210 mV J22 Foro S H+ SH B TO1 T er inale_OU T m
T4 T ras fo_1 /2
OU T -
F ILO T A
T R A FO _P N
J9
T1 1 /200 25A
J10
Wiring diagram power board
+5V +5V C20 100n 50V X7R 5 EN1 3
R 55 1K 0805 5%
R 57 10K 0805 5%
14 1 +5V 7
U 7A 40106 2
R 33 4K 7 0805 1% 3 T P8 T es t_Po in t T P9 T es t_Po in t 8 U 7D 40106 R 34 470K 0805 1% C13 100n 50V X7R 1
17V8 4
U 4B CD4066BC +5V 2 R 27 1K 0805 5%
C22 220n 50V X7R
1 D28 B A S 40-04
C10 100n 50V X7R 4 T P4 T es t_P o in t 7 U 3B LM 324D 0 ..10 V

SET
2 D36 B AV70 1
2 3
11
10 U 7E 40106
D22 BA S 40-04 C16 100n 50V X7R +5V
5 6 11
+5V J3 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
D R+ T A+ TA SH S H+ PO T -IN VCH ECK CADM CAD A CAD 1 CAD 2 SW LED
17V8
R 29 10K 0805 5%
R 30 1K 0805 5%
14 13 EN1 2 7
C12 100n 50V X7R 17V8
U 4A CD4066BC
R 16 4K7 0805 1%
R 17 4K7 0805 1%
R 59 4K7 0805 5%
VO L T+ T AR+ T AR FAU L T
Q7 BC807 T P1 T es t_P o in t
R 53 39K 0805 1%
R 10 13K 0805 1%
T P5 T es t_P o in t 1 U 1A MC33074D 2
A L LARM
3 +5V 2 T P2 T es t_P o in t 11
70354-301
R 23 2K0 0805 1% 11
C7 10n 50V X7R R 87 3K0 0805 1%
SW
13 12 4
14 U 1D MC 33074D R 88 2K0 0805 1% C40 100n 50V X7R

CO R TO
D38 BA S 40-06
S T AR T
+5V 3 R 56 10K 0805 5% 3 +5V C 23 220n 50V X 7R 3 1 D 29 B A S 40 -04 2 U 7B 40106 4 D 37 B A V 70 1 5
T P6 T es t_P o in t 6 U 7C 40106 13
T P7 T es t_P o in t 4 12 U 7F 40106
VR E F
R 31 4K7 0805 1% 4 14 U 3D LM 324D D25 BA S 40-05 1 3 10 9 11 R 38 4K7 0805 1% 6 EN1 9 R 37 1K 0805 5% 2 T P3 T es t_P o in t 8 U 3C LM 324D
OVE R S E T
12 13 11
R 58 1K 0805 5%
R 49 100K 0805 5%
U 4C CD4066BC
0 ..2 ,5 V
R 36 4K 7 0805 1%
12 EN1 10
11
R 32 3K3 0805 1% R 39 4K7 0805 1% R 60 4K7 0805 5%
1 R 51 4K 7 0805 1% C21 100n 50V X7R D23 BA S 40-04
R 35 470K 0805 1%
C15 100n 50V X7R
U 4D CD4066BC +5V 2
CC
Q5 BC817
R 50 4K7 0805 1%
VR E F 17V8 Q1 BC817 R 19
VR E F
T A+
D11 B AV99 11 R 81 39R 1206 1% 2 D12 24V 0W 4 5% 17V8 3 R 79 39R 1206 1% R 80 39R 1206 1% R 82 39R 1206 1%
T P 13 R 83 680R 0805 1% T es t_Po in t
R 18 820R 0805 1%
VCC
R 24 1K 0805 5%
R 15 0R 0805 R 84 200R 0805 1% C14 100p 50V X7R
2 3 5
C11 100n 50V X7R V FB IS EN GND
7K5 0805 1% RT/ T C VR E F 4 8 1 6
COM P OU T
TA -
R 45 1K 0805 5% R 46 4K 7 0805 5%
U2 UC3845AD1
R 21 NM . C8 10n 50V X7R
C9 C42 100n 50V X7R 2n2 50V COG
R ID D U T
11
Q4 BC807
R5 10K 0805 5%
R 42 10K 0805 5% 6 5 D42 7 R 62 1K 0805 5%

D R+
C26 560p 50V COG 17V8 R 63 27K 0805 5% 12
R 12 3K 3 0805 5%
R 64 100K 0805 5%
L L4148 U 1B MC33074D
R 61 6K8 0805 5% 17V8

S T AR T
17V8 6 R6 3K 3 0805 5% D4 G L41G

VO L T+
T P 14 T es t_P o in t 1 U 5B LM 339
VR E F
9 8 12
14 U 5C LM 339
R 48 1K 0805 5%
R 47 47K 0805 5%
7 R 65 9K 1 0805 1% R 14 1K 0805 5% 3
Q3 MM B F170
C19 22u 25V A ll
R ID DU T 17V8 17V8 C17 100n 50V X7R

VR E F
R9 100K 0805 1% R 13 8K 2 0805 1%

SH -
R 40 13K 0805 1% R 25 R 28 4K 7 0805 5% 2K 2 0805 1% Q6 BC 817 R 41 3K 3 0805 1%
5 4 12
U 5A LM 339 2
R 43 33K 0805 5%
VR E F 10 11 3
12
C4 10n 50V X 7R
C6 10n 50V X7R
R 44 2K7 0805 5% T P 15 T es t_P o in t
D26 L L4148
T P 16 T es t_P o in t U 5D LM 339 13
SW
CO R TO CC
C18 22u 25V A ll
C 24 100n 50V X 7R
R 26 10K 0805 5% D2 5V 6 0W 4 5%
Q2 MM B F170 D3 L L 4148 C2 1n 50V X7R C3 10n 50V X7R
R 52 82K 0805 5%
+5V
T A R+ T AR -
1 2
R1 1K 0805 5%
S H+
T P 10 T es t_P o in t 1 U 3A LM 324D R2 4K 7 0805 5%
R 86 NM. . R3 22K 0805 5%
R7 1K 0805 5%
3 2 11
11
T P 12 T es t_Po in t 8 U 1C MC33074D
9 10 C5 NM . 4
D39 L L4148
BAV99 D40 1 3 2
R 54 47R 0805 5%
SH -
C1 1n 50V X 7R
R8 4K 7 0805 1%
C 41 100p 50V X 7R
R 11 1K 0805 5%
+5V T P 11 T es t_P o in t 1 3 D 43 B A S 40 -04 2
17V 8 R4 47K 0805 1%
C25 100n 50V X7R
R 20 4K 7 0805 1%
SET
A L LARM
OVE R S E T
R 22 4K 7 0805 1%
FAU L T
- 10 -
REPAIR GUIDE
EQUIPMENT REQUIRED
ESSENTIAL INSTRUMENTS
1 2 3 4 Dual trace oscilloscope Static load generator Variac 0 - 300v 1500 VA Digital multimeter cod. 802401 (*) cod. 802110 (*) cod. 802402 (*)
USEFUL INSTRUMENTS
5 Unsoldering station 6 Miscellaneous tools
(*)The instruments with codes can be supplied by Telwin. The sale price is available on request.
- 11 -
TROUBLESHOOTING AND REMEDIES
1.0 Disassembling the machine
WARNING: BEFORE PROCEEDING WITH REPAIRS TO THE MACHINE READ THE INSTRUCTION MANUAL CAREFULLY. WARNING: EXTRAORDINARY MAINTENANCE SHOULD BE CARRIED OUT ONLY AND EXCLUSIVELY BY EXPERT OR SKILLED ELECTRICALMECHANICAL PERSONNEL. WARNING: ANY CHECKS CARRIED OUT INSIDE THE MACHINE WHEN IT IS POWERED MAY CAUSE SERIOUS ELECTRIC SHOCK DUE TO DIRECT CONTACT WITH LIVE PARTS.
Every operation should be carried out in complete safety with the power supply cable disconnected from the mains outlet and should only by done by expert or skilled electrical-mechanical personnel. - remove the current adjustment knob on the front panel of the machine (fig. 1); - undo the 4 screws attaching the handle to the top cover (fig. 1). - undo the 8 screws fastening the back and front plastic panels; 4 for the cap (fig. 1). - undo the 2 screws attaching the top cover to the base: 1 screw on each side (fig. 1). - undo the 2 screws fastening the top cover to the metal structure. - slide out the top cover upwards After completing the repairs, proceed in the reverse order to reassemble the cover and do not forget to insert the toothed washer on the ground screw.
2.0 Cleaning the inside of the machine

Using suitably dried compressed air, carefully clean the components of the power source since dirt is a danger to parts subject to high voltages and can damage the galvanic separation between the primary and secondary. To clean the electronic boards we advise decreasing the air pressure to prevent damage to the components. It is therefore important to take special care when cleaning the following parts Fan (fig. 2A) Check whether dirt has been deposited on the front and back air vents or has damaged the correct rotation of the blades, if there is still damage after cleaning replace the fan. Power board (figs. 2A and 2B): - rheofores of IGBT's Q6, Q7, Q8, Q9; - rheofores of recirculating diodes D37, D38; - rheofores of secondary power diodes D46, D47, D48, D49, D51; - thermostat ST2 on power transformer; - thermostat ST1 on secondary diode dissipator; - control board.
GENERAL REPAIR INSTRUCTIONS

The following is a list of practical rules which must be strictly adhered to if repairs are to be carried out correctly. A) When handling the active electronic components, the IGBT's and Power DIODES in particular, take elementary antistatic precautions (use antistatic footwear or wrist straps, antistatic working surfaces etc.). B) To ensure the heat flow between the electronic components and the dissipator, place a thin layer of thermo-conductive grease (e.g. COMPOUND GREASIL MS12) between the contact zones. C) The power resistors (should they require replacement) should always be soldered at least 3 mm above the board. D) If silicone is removed from some points on the boards, it should be re-applied. N.B. Use only non-conducting neutral or oximic reticulating silicones (e.g. DOW CORNING 7093). Otherwise, silicone that is placed in contact with points at different potential (rheophores of IGBT's, etc.) should be left to reticulate before the machine is tested. E) When the semiconductor devices are soldered the maximum temperature limits should be respected (normally 300C for no more than 10 seconds). F) It is essential to take the greatest care at each disassembly and assembly stage for the various machine parts. G) Take care to keep the small parts and other pieces that are dismantled from the machine so as to be able to position them in the reverse order when re-assembling (damaged parts should never be omitted but should be replaced, referring to the spare parts list given at the end of this manual). H) The boards (repaired when necessary) and the wiring should never be modified without prior authorisation from Telwin. I) For further information on machine specifications and operation, refer to the Instruction Manual. J) WARNING! When the machine is in operation there are dangerously high voltages on its internal parts so do not touch the boards when the machine is live.
3.0 Visual inspection of the machine

Make sure there is no mechanical deformation, dent, or damaged and/or disconnected connector. Make sure the power supply cable has not been damaged or disconnected internally and that the fan works with the machine switched on. Inspect the components and cables for signs of burning or breaks that may endanger operation of the power source. Check the following elements: Main power supply switch (fig. 2A) Use the multimeter to check whether the contacts are stuck together or open. Probable cause: - mechanical or electric shock (e.g. bridge rectifier or IGBT in short circuit, handling under load). Current potentiometer R49 (fig. 3) Probable cause: - mechanical shock. Relay K1, K2 (fig. 3) Probable cause: - see main power supply switch. N.B. If the relay contacts are stuck together or dirty, do not attempt to separate them and clean them, just replace the relay. Electrolytic capacitors C27,C29, C30, C31 (fig. 3) Probable cause: - mechanical shock; - machine connected to power supply voltage much higher than the rated value;
- 12 -
broken rheophore on one or more capacitor: the remainder will be overstressed and become damaged by overheating; - ageing after a considerable number of working hours; - overheating caused by thermostatic capsule failure. IGBT's Q6, Q7, Q8, Q9 (fig. 4) Probable cause: - discontinuation in snubber network; - fault in driver circuit; - poorly functioning thermal contact between IGBT and dissipator (e.g. loosened attachment screws:check); - excessive overheating related to faulty operation. Primary diodes D37, D38 (fig. 4) Probable cause: - excessive overheating related to faulty operation. Secondary diodes D46, D47, D48, D49, D51 (fig. 4) Probable cause: - discontinuation in snubber network; - poorly functioning thermal contact between IGBT and dissipator (e.g. loosened attachment screws:check); - faulty output connection. Power transformer and filter reactance (fig. 2A) Inspect the windings for colour changes. Probable causes: - power source connected to a higher voltage than 280Vac; - ageing after a substantial number of working hours; - excessive overheating related to faulty operation. powered and therefore the operator is exposed to the danger of electric shock. The tests described below can be used to check the operation of the power and control parts of the power source. 6.1 Preparation for testing
A) Set up the oscilloscope with the voltage probe x10 connected between pin 2 (DRAIN) of Q4 and the earth on the case of U5 (fig. 3).
B) Set up the multimeter in DC mode and connect the prods to the OUT+ and OUT- bump contacts. C) Position the potentiometer R49 on maximum (turn clockwise as far as it will go). D) Position the switch SW1 in MMA. E) Connect the power supply cable to a single-phase variac with variable output 0-300 Vac. 6.2 Tests for the TECHNOLOGY 175 -210-188CE/GE A) Switch on the variac (initially set to the value 0 V), switch off the main switch on the power source and increase the variac voltage gradually to 230 Vac and make sure: - the green power supply LED D43 lights up (fig. 3), - the fan for the power transformer starts up correctly, - the pre-charge relay K1 commutes (fig. 3), - the unloads relay K2 commutes (fig. 3), - for voltages close to the rated power supply value (230Vac 15%) the power source is not in alarm status (yellow LED D39 off). NB. if the power source stays in alarm status permanently, there could be a fault in the control board (in any case, proceed to make the other tests) B) Make sure the waveform shown on the oscilloscope resembles Fig. A.
4.0 Checking the power and signal wiring

It is important to check that all the connections are in good condition and the connectors are inserted and/or attached correctly. To do this, take the cables between finger and thumb (as close as possible to the fastons or connectors) and pull outwards gently: the cables should not come away from the fastons or connectors. N.B. If the power cables are not tight enough this could cause dangerous overheating.
FIGURA A
5.0 Electrical measurements with the machine switched off

A) With the multimeter set in diode testing mode check the following components (junction voltages not less than 0.2V): - rectifier bridge D31, D32 (fig. 3); - IGBT's Q6, Q7, Q8, Q9 (absence of short circuits between collector-gate and between emitter-collector fig. 4); - secondary board diodes D46, D47, D48, D49, D51 between anode and cathode (fig. 4). The secondary diodes can be checked without removing the power board: with one prod on the secondary board dissipator diodes and the other in sequence on the two power transformer outlets; - MOSFET Q4 (absence of short circuits between drain-gate and drain-source (fig. 4). B) With the multimeter set in ohm mode check the following components: - resistor R1: 47ohm (pre-charge fig. 3); - resistor R14: 3.3ohm (unloads fig. 3); - resistors R44, R45: 22ohm (primar y snubber fig. 3); - resistor R41: 10ohm (secondary snubber fig. 3); - thermostat continuity test on the power transformer: clean the resin from the bump contacts of ST2 (J2) and measure the resistance between the two bump contacts, it should be approx. 0 ohm (fig. 2B).
SETTINGS: - PROBE x10; - 5V/Div; - 5sec/Div. VERIFY THAT: - FREQUENCY IS 52KHz 10%; - AMPLITUD IS 22V 10%.
6.0 Electrical measurements with the machine in operation

WARNING! Before proceeding with faultfinding, we should remind you that during these tests the power source is
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N.B. if no signal is present, it may be necessary to replace the MOSFET Q4 (fig. 3). C) With the multimeter set in volt mode make sure that (fig. 3): - voltage between the negative of diode bridge D31 (-) and the catode D11 (-) is equal to +40V 10%; - voltage between the negative of diode bridge D31 (-) and the pin 3 of Q2 (+) is equal to +17.8V 5%; - voltage between the negative of diode bridge D31 (-) and the pin 3 of U5 (+) is equal to +5V 5%; - voltage between the pads V1- and V1+ is equal to +14V 5% ; - voltage between the pads V2- and V2+ is equal to +14V 5%; D) Set up the dual trace oscilloscope. Connect the probe CH1(x100) to the Q8 collector and probe CH2 (x10) to the
gate, also of Q8. The earth connections are both made to the emitter of Q8. E) Make sure the waveform displayed on the oscilloscope resembles fig. B.
FIGURA B
SETTINGS: - PROBE CH1 x100; - 100 V/Div; - PROBE CH2 x10; - 10V/Div; - 5sec/Div. TIME TOLLERANCES 20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V 10%; - POSITIVE AMPLITUDE ON CH2 IS +19V 10%; - NEGATIVE AMPLITUDE ON CH2 IS -2V 10%.
This is the reference code for requesting a replacement: Telwin may supply boards that are compatible but with different codes. Warning: before inserting a new board check it carefully for damage that may have occurred in transit. When we supply a board it has already been tested and so if the fault is still present after it has been replaced correctly, check the other machine components. Unless specifically required by the procedure, never alter the board trimmers. 7.1 Removing the power board (fig. 2A) If the fault is in the power board remove it from the bottom as follows: - with the machine disconnected from the main supply, disconnect all the wiring connected to the board; - remove the current adjustment knob on the front panel of the machine ( fig. 1); - remove any bands constraining the board (e.g. on the power supply cable and connections to primary); - undo the 3 screws fastening the board to the bottom (fig. 2B); - remove the board from the metal structure, lifting it upwards. N.B. for assembly proceed in the reverse order and remember to insert the toothed washer on the earth screw. A) Please read the procedure for replacing the IGBT's carefully: (fig. 4). The 4 IGBT's are attached to 2 different dissipators and whenever a replacement is required, both IGBT's should be all replaced. - undo the screws attaching the dissipator to the board to replace Q6, Q7 (fig. 2B); - undo the screws attaching the dissipator to the board to replace Q8, Q9 (fig. 2B); - remove the 4 IGBT's and the 2 diodes D37, D38 by unsoldering the rheofores and then clean the solder from the printed circuit bump contacts; - remove the 2 dissipators from the board; - undo the screws locking the 4 IGBT's. Before making the replacement make sure the components piloting the IGBT's are not also damaged: - with the multimeter set in ohm mode make sure there is no short circuit on the PCB between the 1 st and 3rd bump contacts (between gate and emitter) corresponding to each component; - alternatively, resistors R42, R43, R46 and R47 could have burst and/or diodes D21, D22, D23 and D24 may be unable to function at the correct Zener voltage (this should have shown up in the preliminary tests); - clean any irregularity or dirt from the dissipators. If the IGBT's have burst the dissipators may have been irreversibly damaged: in this case they should be replaced; - apply thermo-conductive grease following the general instructions.- Insert the new IGBT's between the dissipator and the spring, taking care not to damage the component during assembly (the spring should be inserted under pressure on the dissipator so as to lock the component); - place the dissipators with the new IGBT's and primary diodes D37 and D38 (WARNING! Make sure there is insulation between the case of diode D38 and the dissipator) in the PCB bump contacts, placing 4 spacers between the dissipator and the PCB (2 for each dissipator) and fasten them down with the screws (torque wrench setting for screws 1 Nm 20%);
- 14 -
F) Repeat this test also for Q6, Q7, Q9 (for Q6 and Q7 use the differential probe). N.B. if the signal is not present there could be a fault in the IGBT driver circuit (fig. 3) or in the control board (fig. 2A, in this case we recommend replacing the board). G) Set the two-channel oscilloscope ready. Connect the probe CH1 (x100) on the collector of Q8 and the mass on the sender of the same Q8 probe CH2 (x10) on the pin 9 of strip J11. The masses are to be connected together on the sender of Q1. Connect the probe CH2 on the pin 5 of J7 and the mass on pin 6 of the same J7. N.B. In case you wish to measure the two wave shapes together as indicated in the figure it is necessary to use the differential probe (1/20). H) Make sure the waveform displayed on the oscilloscope resembles fig. C and that the output voltage over OUT+ and OUT - is equal to +100Vdc10%.
FIGURA C
SETTINGS: - PROBE CH1 x100 - 100V/Div; - P R O B E C H 2 DIFFERENTIAL PROBE (1/20); - 100mV/Div; - 5sec/Div. TIME TOLLERANCES 20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V 10%; - P O S I T I V E AMPLITUDE ON CH2 50mV 10%. - N E G A T I V E AMPLITUDE ON CH2 -150mV 10%
I) Switch the power source on again and make sure that, following the brief start up time, the machine is not in alarm status (the yellow alarm LED D39 is off, fig. 3). N.B. If the machine remains in alarm status (and this is not due to a fault in the control board) there could be a fault R9 or D7 (fig. 3).
7.0 Repairs, replacing the boards

If repairing the board is complicated or impossible, it should be completely replaced. The board is identified by a 6-digit code (printed in white on the component side after the initials TW).
solder the terminals taking care not to let the solder run along them; on the welding side cut away the protruding part of the rheofores and check they are not shorted (between the gate and emitter in particular). (1/20), on the pin 5 of J7 (control card) and the mass on pin 6 of the same strip J7. C) Set up the multimeter in DC mode and connect the prods to the OUT+ and OUT- bump contacts. D) Connect the power supply cable to the 230Vac power supply. WARNING! During tests the operator must avoid contact with the metal parts of the torch because of the presence of dangerous, high voltage. 1.2 Tests for the TECHNOLOGY 175-210-188CE/GE A) Minimum load test: - set up the static load generator with the switch settings as in the table in Fig. D; - on the front panel position the current potentiometer at (approx.) half way. - switch on the main switch; - activate the statico load generator and make sure that: - the waveforms displayed on the oscilloscope resemble those in Fig. D; - the output current is +6Adc20%, and the output voltage is +20.2Vdc20%. - deactivate the static load generator and switch off the main switch.
B) Please read the procedure for replacing the secondary board diodes carefully (fig. 4): The SECONDARY DIODES are attached to the same dissipator, and when a replacement is required, all of them should be replaced: - undo the screws attaching the dissipator to the board, to replace diodes D46, D47, D48, D49 and D51; - remove the secondary diodes unsoldering the rheofores and cleaning any solder from the bump contacts on the board; - remove the dissipator from the board; - remove the spring locking the diodes; - clean any irregularity or dirt from the dissipator. If the diodes have burst the dissipator may have been irreversibly damaged: in this case it should be replaced; - apply thermo-conductive grease following the general instructions; - insert the new diodes between the dissipator and the spring, taking care not to damage the component during assembly (the screw should be inserted under pressure on the dissipator so as to lock the component); - place the dissipator with the new components in the PCB bump contacts and fasten them down with the screws (torque wrench setting for screws 1 Nm 20%); - solder the terminals taking care not to let the solder run along them; - on the soldering side cut away the protruding part of the rheofores and check they are not shorted (between cathode and anode); N.B. make sure resistor R41 and capacitor C32 on the snubber have been soldered to the PCB correctly (fig. 3). C) Please read the procedure for replacing the control board (fig. 3): Whatever fault occurs in the control board, we strongly recommend its replacement without attempts at repair. To remove it, cut and then unsolder from the power board the connector keeping it fixed perpendicular to the PCB, replace it and re-solder the connector.
FIGURA D
SETTINGS: - PROBE CH1 x100 - 100V/Div; - PROBE CH2 differential probe (1/20) - 100mV/Div. - 5 sec/Div. TIME TOLLERANCES 20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V 10%. - AMPLITUDE ON Ch2 IS 60mV 10%.
1 2 3 4 5 6 1 0 0 0 0 0
Switch number Position number
TESTING THE MACHINE

Tests should be carried out on the assembled machine before closing it with the top cover. During tests with the machine in operation never commute the selectors or activate the ohmic load contactor. WARNING! Before proceeding to test the machine, we should remind you that during these tests the power source is powered and therefore the operator is exposed to the danger of electric shock. The tests given below are used to verify power source operation under load. 1.1 Preparation for testing. A) Connect the power source to the static load generator using cables fitted with the appropriate dinse connectors (code 802110). B) Set the two channel oscilloscope by connecting the probe CH1 (x100) on the collector of Q8 and the mass on the sender of the same Q8. Connect the probe CH2, of differential type
- 15 -
B) Intermediate load test: - set up the ohmic load with the switch settings as in the table in fig. E; - on the front panel turn the current potentiometer to 60A (approx. half-way); - start up the ohmic load and make sure that: - the waveforms displayed on the oscilloscope resemble those in Fig. E; - the output current is equal to +60Adc 10% and the output voltage is equal to +22.4Vdc 10%. - switch off the ohmic load.
FIGURA E
SETTINGS: - PROBE CH1 x100 - 100V/Div; - PROBE CH2 differential probe (1/20); - 100mV/Div; - 5 sec/Div. TIME TOLLERANCES 20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V 10%. - AMPLITUDE ON CH2 IS 120mV 10%.
using trimmer R48 (fig. 3). switch off the ohmic load.
FIGURA G
SETTINGS: - PROBE CH1 x100 - 100V/Div; - PROBE CH2 differential probe (1/20); - 200mV/Div; - 5sec/Div. TIME TOLLERANCES 20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V 10%; - AMPLITUDE ON CH2 IS 200mV 10%.
1 2 3 4 5 6 2 2 2 1 1 1
C) Rated load test for TECHNOLOGY 175: - set up the ohmic load with the switch settings as in the table in fig. F; - on the front panel turn the current potentiometer to maximum (turn clockwise as far as it will go); - start up the ohmic load and make sure that: - the waveforms displayed on the oscilloscope resemble those in fig. F; - the output current is equal to +160Adc 5% and the output voltage is equal to +26.4Vdc 5%; if the output current reading is not 160A 5%, adjust the current using trimmer R48 (fig. 3). - switch off the ohmic load.
1 2 3 4 5 6 3 3 3 3 3 2
FIGURA F
SETTINGS: - PROBE CH1 x100 - 100V/Div; - P R O B E C H 2 differential probe (1/20) - 200mV/Div; - 5sec/Div. TIME TOLLERANCES 20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V 10%; - LAMPLITUDE ON CH2 IS 180mV 10%.
E) Rated load test for TECHNOLOGY 188CE/GE: - set up the ohmic load with the switch settings as in the table in fig. H; - on the front panel turn the current potentiometer to maximum (turn clockwise as far as it will go); - start up the ohmic load and make sure that: - the waveforms displayed on the oscilloscope resemble those in fig. H; - the output current is equal to +140Adc 5% and the output voltage is equal to +25.6Vdc 5%; if the output current reading is not 140A 5%, adjust the current using trimmer R48 (fig. 3). - switch off the ohmic load.
FIGURA H
SETTINGS: - PROBE CH1 x100 - 100V/Div; - PROBE CH2 differential probe (1/20); - 200mV/Div; - 5V/Div; - 5sec/Div. TIME TOLLERANCES 20%. VERIFY THAT: - AMPLITUDE ON CH1 IS 320V 10%; - AMPLITUDE ON CH2 IS 220mV 10%.
1 2 3 4 5 6 3 3 3 3 2 2
D) Rated load test for TECHNOLOGY 210: - set up the ohmic load with the switch settings as in the table in fig. G; - on the front panel turn the current potentiometer to maximum (turn clockwise as far as it will go); - start up the ohmic load and make sure that: - the waveforms displayed on the oscilloscope resemble those in fig. G; - the output current is equal to +180Adc 5% and the output voltage is equal to +27.2Vdc 5%; if the output current reading is not 180A 5%, adjust the current
- 16 -
1 2 3 4 5 6 3 3 3 2 2 2
F) Checking the secondary diode voltages: - set up the dual trace oscilloscope, connecting probe CH1 x 100 to the anode of diode D46 and probe CH2x100 to the anode of diode D51. Earth connections are both made to the secondary dissipator; - remove the multimeter from the OUT+ and OUT- bump contacts;
set up the static load generator with the switch settings as in the table in fig. F, G or H; on the front panel position the current potentiometer to the maximum (turn the knob clockwise as far as it will go) and switch on the main switch; activate the static load generator and make sure that the waveforms displayed on the oscilloscope resemble those in fig. I; deactivate the static load generator and switch off the main switch.
FIGURA H
SETTINGS: - PROBE CH1 x100 - 50V/Div; - PROBE CH2 x100; - 50V/Div; - 5sec/Div. TIME TOLLERANCES 20%. VERIFY THAT: - MAX REVERSE AMPLIDUTE ON CH1 AND CH2 DOES NOT EXCEED A 250V.
G) Running time check and closing the machine With the load status as in fig. F, G or H and the current adjustment potentiometer on maximum, switch on the power source and leave it in operation until the thermostatic capsules trigger (machine in alarm status). Check the correct positioning of the internal wiring and finally re-assemble the machine. H) Welding test With the power source set up according to the instructions in the handbook make a test weld at 80A (electrode diameter 2.5 mm). Check the dynamic behaviour of the power source.
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ILLUSTRATIONS
FIG. 1
SCREWS FASTENING HANDLE SCREWS FASTENING HANDLE CURRENT REGULATION POTENTIOMETER POWER SUPPLY LED SCREWS FASTENING BACK PANEL
ALARM LED WELDING PROCEDURE FUNCTION SELECTOR DINSE SOCKET
SCREWS FASTENING TOP COVER
SCREWS FASTENING FRONT PANEL
FIG. 2A
POWER SUPPLY INTERRUPTOR FILTER CAPACITORS DIODES BRIDGE DISSIPATOR FAN WIRE CONTROL BOARD
FIG. 2B
NUTS FASTENING METALLIC STRUCTURE BUMP CONTACTS THERMOSTAT ST1 (J1,J2) BUMP CONTACTS FAN V1,V2 NUTS RHEOFORES FASTENING Q6, Q7 METALLIC STRUCTURE
Q6, Q7 DISSIPATOR SCREWS FASTENING
FAN BOTTOM IGBT DISSIPATORS POWER TRANSFORMER DIODES SECONDARY DISSIPATORS INDUCTANCE
Q8, Q9 DISSIPATOR SCREWS FASTENING SECONDARY DISSIPATOR SCREWS FASTENING

RHEOFORES
Q8, Q9
NUTS FASTENING METALLIC STRUCTURE
FIG. 3
D31, D32 R14 K1, K2 R40 R41 V1, V2 U5 D7,R9 Q2 R48 J7
FIG. 4
IGBT Q6, Q7
PRIMARY DIODE D37
SECONDARY DIODES D46,D47,D48,D49,D51
C29 C31
R49
D43 C30 D39
Sw1
C32
R44
R45
Q4
St2
R38
PRIMARY DIODE D38
IGBT Q8, Q9
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ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO
TECHNOLOGY 175-210
23 1 22 25 12 13 21 24
15 11
17
10
16 18
26
27
28
20
14
19
Per richiedere i pezzi di ricambio senza codice precisare: codice del modello; il numero di matricola; numero di riferimento del particolare sull'elenco ricambi. Pour avoir les pieces detachees, dont manque la reference, il faudra preciser: modele, logo et tension de I'appareil; denomination de la piece; numero de matricule. When requesting spare parts without any reference, pls specify: model-brand and voltage of machine; list reference number of the item; registration number. Wenn Sie einen Ersatzteil, der ohne Artikel Nummer ist, benoetigen, bestimmen Sie bitte Folgendes: Modell-zeichen und Spannung des Geraetes; Teilliste Nuemmer;
- 19 -
REF.
ELENCO PEZZI DI RICAMBIO PIECES DETACHEES SPARE PARTS LIST ERSATZTEILLISTE PIEZAS DE REPUESTO
REF.
REF.
REF.
REF.
1 2 3 4 5 6 7 8 9
Potenziometro Potentiometre Potentiometer Potentiometer Potenciometro Resistenza Resistance Resistor Wiederstand Resistencia Condensatore Condensateur Capacitor Kondensator Capacitor Diodo Diode Diode Diode Diodo Raddrizzatore Redresseur Rectifier Gleichrichter Rectificador Resistenza Resistance Resistance Widerstand Resistencia Scheda Controllo Carte Controle Control Board Steuerungskarte Tarjeta Control Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip122 Bjt Tip122 Bjt Tip122 Bjt Tip122 Bjt Tip122
10 11 12 13 14 15 16 17 18
Rele' Relais Relais Relais Relais Interruttore Interrupteur Switch Schalter Interruptor Manopola Potenziometro Poignee Pour Potentiometre Knob For Potentiometer Potentiometergriff Malja Por Resist.electr.variable Deviatore Gareur Switch Schalter Interruptor Termostato Thermostat Thermostat Thermostat Termostato Cavo Alim. Cable Alim. Mains Cable Netzkabel Cable Alim. Ventilatore Ventilateur Fan Ventilator Ventilador Induttanza Filtro Inductance Filter Filter Inductance Filter Drossel Induccion Filtro Trasformatore Ausiliario Transformateur Auxiliaire Auxiliary Transformer Hilfstransformator Transformador Auxiliar
19 20 21 22 23 24 25 26 27
Induttanza Inductance Inductance Drossel Induccion Trasformatore Potenza Transformateur Puissance Power Transformer Leistungstransformator Transformador De Potencia Frontale Partie Frontal Front Panel Geraetefront Frontal Retro Partie Arriere Back Panel Rueckseite Trasera Manico Poignee Handle Handgriff Manija Presa Dinse Prise Dix Dinse Socket Dinse Steckdose Enchufe Dinse Kit Mantello Kit Capot Cover Kit Deckel Kit Kit Panel De Cobertura Kit Fondo Kit Chassis Bottom Kit Bodenteil Kit Kit Fondo Kit Igbt + Diodo Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diodo
28
Kit Scheda Completa Kit Platine Complete Complete Control Pcb Kit Komplette Steurungskarte Kit Kit Tarjeta De Controlo Completa
TECHNICAL REPAIR CARD. In order to improve the service, each servicing centre is requested to fill in the technical card on the following page at the end of every repair job. Please fill in this sheet as accurately as possible and send it to Telwin. Thank you in advance for your co-operation!
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ELENCO PEZZI DI RICAMBIO - LISTE PIECES DETACHEES SPARE PARTS LIST - ERSATZTEILLISTE - PIEZAS DE REPUESTO
TECHNOLOGY 188CE/GE
23 1 22 25 12 13 21 24
15 11
17
10
16 18
29
26
27
28
20
14
19
Per richiedere i pezzi di ricambio senza codice precisare: codice del modello; il numero di matricola; numero di riferimento del particolare sull'elenco ricambi. Pour avoir les pieces detachees, dont manque la reference, il faudra preciser: modele, logo et tension de I'appareil; denomination de la piece; numero de matricule. When requesting spare parts without any reference, pls specify: model-brand and voltage of machine; list reference number of the item; registration number. Wenn Sie einen Ersatzteil, der ohne Artikel Nummer ist, benoetigen, bestimmen Sie bitte Folgendes: Modell-zeichen und Spannung des Geraetes; Teilliste Nuemmer; Registriernummer.
- 21 -
REF.
REF.
REF.
REF.
REF.
1 2 3 4 5 6 7 8 9
Potenziometro Potentiometre Potentiometer Potentiometer Potenciometro Resistenza Resistance Resistor Wiederstand Resistencia Condensatore Condensateur Capacitor Kondensator Capacitor Diodo Diode Diode Diode Diodo Raddrizzatore Redresseur Rectifier Gleichrichter Rectificador Resistenza Resistance Resistance Widerstand Resistencia Scheda Controllo Carte Controle Control Board Steuerungskarte Tarjeta Control Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip50 Bjt Tip122 Bjt Tip122 Bjt Tip122 Bjt Tip122 Bjt Tip122
10 11 12 13 14 15 16 17 18
Rele' Relais Relais Relais Relais Interruttore Interrupteur Switch Schalter Interruptor Manopola Potenziometro Poignee Pour Potentiometre Knob For Potentiometer Potentiometergriff Malja Por Resist.electr.variable Deviatore Gareur Switch Schalter Interruptor Termostato Thermostat Thermostat Thermostat Termostato Cavo Alim. Cable Alim. Mains Cable Netzkabel Cable Alim. Ventilatore Ventilateur Fan Ventilator Ventilador Induttanza Filtro Inductance Filter Filter Inductance Filter Drossel Induccion Filtro Trasformatore Ausiliario Transformateur Auxiliaire Auxiliary Transformer Hilfstransformator Transformador Auxiliar
19 20 21 22 23 24 25 26 27
Induttanza Inductance Inductance Drossel Induccion Trasformatore Potenza Transformateur Puissance Power Transformer Leistungstransformator Transformador De Potencia Frontale Partie Frontal Front Panel Geraetefront Frontal Retro Partie Arriere Back Panel Rueckseite Trasera Manico Poignee Handle Handgriff Manija Presa Dinse Prise Dix Dinse Socket Dinse Steckdose Enchufe Dinse Kit Mantello Kit Capot Cover Kit Deckel Kit Kit Panel De Cobertura Kit Fondo Kit Chassis Bottom Kit Bodenteil Kit Kit Fondo Kit Igbt + Diodo Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diode Kit Igbt + Diodo
28 29
Kit Scheda Completa Kit Platine Complete Complete Control Pcb Kit Komplette Steurungskarte Kit Kit Tarjeta De Controlo Completa Induttanza Filtro Ge Inductance Filter Ge Ge Filter Inductance Ge Filter Drossel Induccion Filtro Ge
Scheda tecnica di riparazione: Con lo scopo di migliorare il servizio, alla fine di ogni riparazione chiediamo ad ogni Centro Assistenza di compilare e restituire a Telwin la scheda tecnica riportata nella pagina seguente.
- 22 -
Official servicing centers Repairing sheet

Date: Inverter model: Serial number: Company: Technician: In which place has the inverter been used? Building yard Workshop Others: Supply: Power supply From mains without extension From mains with extension m: Mechanichal stresses the machine has undergone to Description:
Dirty grade Dirty inside the machine Description:

Kind of failure Component ref.
Rectifier bridge Electrolytic capacitors Relais In-rush limiter resistance IGBT Snubber Secondary diodes Potentiometer Others
Substitution of primary power board: yes Troubles evinced during repair :
no
- 23 -
TELWIN S.p.A. - Via della Tecnica, 3 36030 VILLAVERLA (Vicenza) Italy Tel. +39 - 0445 - 858811 Fax +39 - 0445 - 858800 / 858801 E-mail: telwin@telwin.com http://www.telwin.com

Inverter Technology 175 210 188GE

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Inverter Technology 175 210 188GE

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TECHNOLOGY 175-210-188CE/GE TECNICA 140.1 - 142

TROUBLESHOOTING AND REPAIR MANUAL

POWER SUPPLY LED

PRIMARY CURRENT READER AND LIMITER

SECONDARY DIODE THERMOSTAT

POWER TRANSFORMER THERMOSTAT

OPERATION AND WIRING DIAGRAMS

MAXIMUM CURRENT ADJUSTMENT

WELDING PROCEDURE FUNCTION SELECTOR

2) Triggering of thermostatic capsule on secondary diodes.

(22) WELDING PROCEDURE FUNCTION SELECTOR

(10) SECONDARY FILTER EMC

(9) INDUCTANCE AND SHUNT

(8) SECONDARY DIODES

(7) POWER TRANSFORMER

(11) AUXILIARY POWER SUPPLY (6) CURRENT TRANSFORMER

(15) TRANSFORMER PILOT

(3) RECTIFIER BRIDGE

(13) SEPARATOR TRANSFORMER

(1) PRIMARY EMC FILTRE

POW E R PCB CON T RO L PCB

+5V +17V8 D R+ GND T A+ TA SH S H+ VO L T VO L T+ PO T _ IN T AR+ T AR VCH ECK FAU L T

Wiring general diagram - TECHNOLOGY 175 - 210 -188 CE/GE

-6V1J21 V 2+ SH V2R 38 S hun t J22

C29 ,C30 ,C31

T ECHNO LOG Y 175

T ECHNO LOG Y 210

T ECHNO LOG Y 188G E / E C

T P1 T P2 T P3 JP 1 V .T . Q7 V .T . C33 10n 630V K P K2 V .T .

R 40 47R 8W 5% T P 39 R 42 1R 0W 25 5% D34 NM. . R 44 20R 13W 5% D33 R U R P 860

Fas ton- 6 ,3x0 ,8 M H2 D is s patore i H3 D is s patore i T P 37 R 46 1R 0W 25 5% Q8 V .T . T P 38 Q9 V .T .

Fas ton- 6 ,3x0 ,8 M

Wiring diagram power board - primary

Fas ton- 6 ,3x0 ,8 M

C25 4n7 250V K P

C26 4n7 250V K P

C34 10n 630V K P

T A+ TA SH S H+ VO L T VO L T+ PO T IN T A R+ TAR VC H E C K FAU L T C A DM C AD A C AD 1 C AD 2 SW LED

C44 100u 25V A ll

T2 230 /18 4VA

C36 T P 29 1n 100V X7R T P 28

D11 B Y V27-200 V1 12Vdc +V2 V2 12Vdc

C37 1n 100V X7R

Wiring diagram power board - power / driver

C11 100u 63V A ll

C43 47u 25V A ll

J1 IN /OU T R 11 10K 0W 25 5% Q3 BC337

MOD E L C20 100n 63V M K T B D47 = N M . . D47 = S T T H 6003CW B R 60 1K 0W 25 5%

D46 = S T T H 6003CW D48 = S T T H 6003CW D47 = N M . .

D44 NM. . 3 D46 V .T . VO L T S T1 80 C VO L T+

Wiring diagram power board - secondary

D 48 V .T . 3 D 27 NM. . D49 S T T H 6003CW D50 NM. . H5 1 2 1

-93 D47 V .T . D29 NM. . R 41 10R 5W 5% T P 15 T P 14 J5 S P+ SP J6 T P 12 T P 13 TA T A+

R 37 100K 0W 25 5% 2 D51 S T T H 6003CW

U 4B CD4066BC +5V 2 R 27 1K 0805 5%

C22 220n 50V X7R

C10 100n 50V X7R 4 T P4 T es t_P o in t 7 U 3B LM 324D 0 ..10 V

D22 BA S 40-04 C16 100n 50V X7R +5V

C12 100n 50V X7R 17V8

C7 10n 50V X7R R 87 3K0 0805 1%

14 U 1D MC 33074D R 88 2K0 0805 1% C40 100n 50V X7R

+5V 3 R 56 10K 0805 5% 3 +5V C 23 220n 50V X 7R 3 1 D 29 B A S 40 -04 2 U 7B 40106 4 D 37 B A V 70 1 5

R 32 3K3 0805 1% R 39 4K7 0805 1% R 60 4K7 0805 5%

1 R 51 4K 7 0805 1% C21 100n 50V X7R D23 BA S 40-04

C15 100n 50V X7R